Ai-Optimized 3D-Printed Abutments In Prosthodontics

To overcome the limitations of traditional abutments in biomechanical adaptation, this study integrates AI-driven biomechanical optimization and additive manufacturing to evaluate 3D-printed abutments' precision, stability, and biocompatibility. (1)AI Modeling: Finite element models from 128 CT scans predicted bone stress (>15 MPa threshold) from January 2023 to January 2025. Dynamic topology optimization refined abutment morphology (target: 30% stress reduction). (2)SLM Fabrication: Titanium abutments (Ti-6Al-4V ELI) were 3D-printed (SLM: 280W, 30μm layers) with HIP post-processing (100MPa, 920°C), achieving >99.9% density and Ra<2μm roughness. (3)Validation: Accuracy: Industrial CT (1μm) measured interface gaps; ISO 14801 fatigue testing (5×10⁶ cycles, 150N) assessed stability. Biocompatibility: Human gingival fibroblasts (CCK-8 assay) and porcine models (Micro-CT BV/TV) evaluated biological responses. Microbial Resistance: S. mutans biofilm assays quantified plaque adhesion. AI-optimized abutments reduced stress concentration by 48% (p<0.001) and exhibited superior mechanical performance (interface gaps: 18.3±2.4μm vs. 53.6±5.1μm, p<0.001; yield strength: 825±15MPa vs. 720±20MPa, p=0.001). Biological validation showed increased cell proliferation (27%, p=0.002) and enhanced osseointegration (BV/TV: 68.5±4.2% vs. 54.1±5.7%, p=0.008), while microbial adhesion decreased by 52% (p<0.01). This AI-driven approach enhances precision, biomechanical stability, and biocompatibility of 3D-printed abutments, offering a transformative solution for complex prosthodontic rehabilitation.